Interlocking component assembly system

ABSTRACT

An interlocking component assembly is made of a plurality of frame components and a plurality of panels. One panel is formed integrally with a respective frame to form a frame and panel component. A channel formed along the entire periphery of each of the frame components enables each of the frame and panel components to be interconnected. During assembly the channel of one frame component is inserted within a channel of another frame component to lock the components together along the length thereof. A plurality of locking tabs are disposed within the channel of each of the plurality of frame components. A plurality of apertures are also disposed within the channel of each of the plurality of frame components, wherein when the channel of a frame component is inserted within the channel of another frame component at least one locking tab is received within a corresponding aperture. This process is repeated until a three-dimensional unit is formed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a flat panel/frame assembly ofstructural multi-sided units which can be assembled to form variousindustry products, and more particularly, to a method of assembling themulti-sided flat panel/frame cube units without additional, separatefasteners.

2. Description of the Related Art

Precision assembly systems (P.A.S.), ready-to-assemble (R.T.A.) andknocked down (K.D.) methods for manufacturing, constructing andassembling square, multi-sided or rectangular cube based products areknown. One disadvantage with the known methods is that ease forassembly/disassembly is low, often requiring numerous fasteners, toolsand personnel to complete the project. Furthermore, even if the numberof fasteners is minimal with such assemblies, the mere presence offasteners decreases the aesthetics of the completed product.

More often than not the fasteners are specially-configured which may ormay not meet local safety requirements. If one fastener is missing orbroken, assembly must be discontinued until a replaced fastener can beobtained. Thus, the use of separate fasteners increases assembly time,costs and frustration for the user/assembler.

U.S. Pat. Nos. 1,735,375, 2,620,251, 2651,557 and 4,691,644 eachdisclose a frame structure which can be assembled of horizontal andvertical members. However, these frame structures require that theassembled members be fixed together with fasteners. Hence, the ease ofassembly is decreased due to cost, time and effort expended by theuser/assembler.

In order to overcome the deficiencies related to P.A.S., R.T.A. or K.D.methods utilizing fasteners, numerous alternative fastener-free productshave been developed. U.S. Pat. No. 4,482,074 to Lalley discloses amultipurpose container of a foldable body blank having a plurality ofslots to receive lugs of first and second head members. Although thecontainer can be assembled without separate fasteners, the cooperativemounting means are complicated and the pieces are not interchangeable.Moreover, each container is independent and although numerous containerscan be stacked, no means are provided for fastening a plurality ofcontainers together to build a unit.

U.S. Pat. No. 4,171,150 and British Patent No. 942,739 each disclose astorage cabinet consisting of a plurality of components which can beassembled by a plurality of engageable members. However, like the patentto Lalley, the structure of the engaging members is different for thesides and top members.

It is desirable to have P.A.S., R.T.A. & K.D. manufacturing and assemblymethods which reduce the need for separate fasteners, but at the sametime allow for a simple and quick interlocking manufacturing,construction and assembly manner.

SUMMARY OF THE INVENTION

One object of the present invention is to provide an interlocking flatpanel/frame manufacturing, construction and assembly process thatrequires no additional, separate mechanical connection devices orfasteners.

Another object of the present invention is provide method for themanufacturing, construction and assembly of structural multi-size,multi-sided square and/or rectangular cube units that can be utilized toconstruct and assemble an unlimited number of products in any industry.

Yet another object of the present invention is to provide aninterlocking flat panel/frame manufacturing, construction and assemblyprocess that requires few non-or minimally-trained persons for assembly.

Still another object of the present invention is to provide aninterlocking flat panel/frame which allows for simple and quick assemblyat either a manufacturer's primary or secondary facility or at acustomer's field location.

The interlocking flat panel/frame of the present invention is capable ofreceiving a plurality of different subassemblies, such as shelving,drawers, doors, dividers etc., to construct functional product unitsthat can be designed to meet various market and industry requirements.

Although the interlocking flat panel/frame product of the presentinvention embodies the P.A.S., R.T.A. & K.D. manufacturing and assemblymethods, when final assembly is completed no unsightly connectors orfasteners which would detract from the aesthetics of the completedproduct are visible.

Another advantage of the interlocking flat panel/frame manufacturing,construction and assembly process of the present invention is thatfreight and transportation costs, warehouse and storage costs, and floorturn rate are reduced. These costs can be reduced by up to 80% versusconventional product unit factory manufacturing and constructionmethods. These cost reductions have no effect on the industryfunctional, aesthetic, or international industry safety standards of thefinished product.

An additional and significant advantage of the present invention is thatvarious connecting methods, concealed or exposed, can be utilized tomeet different market manufacturing, construction and assemblyprocesses. Moreover, the interlocking flat panel/frame manufacturing,construction and assembly process of the present invention can reducecomponent inventory levels by up to 70% depending upon the product unittype. Other associated business inventory investment costs can bereduced by utilizing common components to construct various industryunit products.

In accomplishing these and other objects of the present invention, thereis provided an interlocking component assembly comprising a plurality offrame components and a plurality of panels, wherein each panel formedintegrally with a respective frame to form a frame and panel component.Means interconnect a plurality of the assembled frame and panelcomponents together. The interconnecting means comprise a channel formedalong the entire periphery of each of the frame/panel components. Duringassembly the channel of a frame/panel component is inserted within achannel of another frame/panel component to lock the components togetheralong the length thereof.

The size of a unit made according to the present invention depends uponthe height, width and depth of the frame and panel components. The unitcan be prepared to accept any one or more of a plurality ofsub-components.

These and other objects, features, aspects, and advantages of thepresent invention will become more apparent from the following detaileddescription of the preferred embodiment relative to the accompanieddrawings, in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an expanded, isometric view of a flat panel/frame unitaccording to the present invention.

FIGS. 2A-2D are perspective views of the interlocking flat panel/framecomponents of the present invention.

FIG. 3 is a cross-sectional view of the assembled flat panel/frame unittaken along line I-I of FIG. 1.

FIGS. 4A and 4B are cross-sectional views illustrating the assemblyprocess of the interlocking frames according to the present invention.

FIG. 5 is a perspective view of another embodiment of an interlockingflat panel/frame unit assembled according to the present invention.

FIG. 6 is a cross-sectional view of the assembled flat panel/frame unittaken along line II-II of FIG. 5.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIG. 1, a plurality of vertical interlocking flatpanel/frame components 10, 12, 14 and 16 and horizontal interlockingflat panel/frame components 18 and 20 can be assembled to form aninterlocking flat panel/frame unit according to the present invention.It should be appreciated that a variety of multi-sided orrectangular/square units can be assembled according to the presentinvention, with the specific shapes and sizes of the units beingdictated by industry or customer requirements.

As shown in FIGS. 2 a-2 c, each vertical or horizontal componentcomprises an interlocking frame 12 a, 18 a and an integral flat panel 12b, 18 b respectively. The panels and frames can be made of a variety ofmaterial, such as, metals, plastics, etc. The choice of material isdependent upon the industry (ANSI/BIFMA) requirements, as well ascustomer requirements such as function, cost, price point, etc. Theframes 12, 18 are a unitary-channel shaped construction as describedfurther herein. It should be appreciated that the interlockingcomponents can be comprised of only the interlocking frames and not theintegral frame/panel support.

Referring to FIG. 3, flat panel 14 b is integral with frame 14 a and theflat panel/frame units can be a portion with a skin surface as shown inFIG. 3.

FIGS. 4A and 4B illustrate a method of interlocking the frame/panelcomponents to form the units according to the present invention. Asshown in FIG. 4A, each of the frames are formed of an approximatelyU-shaped channel which extends along the entire circumference of theframe. The channel includes a first leg portion 30 having a lip 31extending perpendicularly from a first end of the channel. A baseportion 32 connects first leg portion 30 with a second leg portion 34.

Leg portion 34 includes a locking tab 24, although only locking tab isshown it should be appreciated that the channel can include a pluralityof locking tabs positioned on either leg portions 30, 34 or base portion32. The actual number and position of the locking tabs on the framesdepend upon the customer/industry requirements. Locking tabs 24 aredesigned to be received within respective apertures 26 also located onthe frames, as shown in FIG. 4B. Like tabs 24, the number andpositioning of apertures 26 depend upon customer/industry requirements.

As shown in FIGS. 4A and 4B, frame 18 is inserted into frame 12 at anangle, indicated by the arrow in FIG. 4A, so that the two framesinterlock at, for example, a 90° angle. It should be appreciated thatother connection angles are contemplated by the present invention. Frame18 is then rotated upward into frame 12 until locking tab 24 is engagedwithin aperture 26. No other devices or fasteners are required toassemble the interlocking flat panel/frame unit according to the presentinvention. As shown in FIG. 4B, when assembled second leg portion 34′ offrame 18 extends flush with base portion 32 of frame 12 to form analmost seamless connection between frames 12 and 18.

Referring to FIG. 5, another embodiment of an interlocking frame/flatpanel unit is shown. The unit includes vertical interlocking flatpanel/frame components 10′, 12′ and 16′ and horizontal interlocking flatpanel/frame components 20′. A plurality of subcomponents areincorporated in an assembled unit. For example, the cube unit caninclude a drawer 40, tub 42 or another type of tray unit. A shelf 44 anddivider 46 can also be incorporated in the unit. The actual finisheddesign and shape of a cube unit is dependent upon customer/industryrequirements. For example, shelf 44 can be of a variety of widths,lengths and depths, fixed within the unit or of adjustable locations.The shelf could also be slidable in and out of the unit by incorporatingslides or runners on the vertical/horizontal panels.

The units could also incorporate frame(s) (not shown) of a variety ofsizes and load capacities, either fixed or adjustable, and slidablewithin the unit. Drawer 40 could also incorporate file suspensiondevices of various sizes, materials and functions. All of thecomponents, as well as the frames/panels can be made of a variety ofmaterials and finishes. The unit can also incorporate a door (not shown)having a variety of designs. For example, the door could be of a louverdesign, a single or double swing door design, either left-side orright-side mounted. Also, the present invention contemplates a door of arolling shutter or sliding design. Locking assemblies of a variety oftypes and specifications, i.e., having a single or multiple lockingpoints, can be incorporated in an assembled unit.

FIG. 6 is a cross-sectional view of the unit of FIG. 5 taken along lineII-II thereof. As shown, frame 10 a′ and integral flat panel 10 c′ canbe assembled with a frame 16 a′ and panel 16 b′ of second frame/panelunit. Likewise, frame 12 a′ can be assembled with frame 16 a′. Eachframe unit has locking tab(s) and aperture(s) as described herein above.

Referring once again to FIG. 1, the procedure or method for assemblingthe unit thereof will be described. Vertical flat side panel/framecomponents 10 and 12 can be attached to vertical front and back flatpanel/frame components 14,16 by interlocking the frames as describedabove with relation to FIGS. 4A and 4B.

Thereafter, each of the horizontal panel/frame components 18 and 20 canbe attached to front panel 14 of the assembled vertical components androtated into position to connect with side vertical frame/panels 10, 14and back vertical frame/panel 16 to form a three-dimensional multi-sidedshaped unit. The assembly sequence can vary from product to product.However, one example of an attachment sequence would be to assemble theside panel/frame units to front and back flat panel/frame units. Next,the top and bottom panel/frames could be interlocked with the front ofthe product and then rotated into position with the side and backpanel/frames.

To prevent twisting or deforming of a frame cross-section of anassembled cube unit, after the materials, size and subcomponents of aunit are selected, the number and location of the locking tabs and holesare established. Thus, the number and location of the locking tabs aredetermined after a specific product with its unique performancespecifications has been established.

In summary, the interlocking panel/frame assembly and method thereofallows for a plurality of multi-sided sized units, made of a variety ofmaterials, and having an infinite number and choice of sub-components.The finished units being dictated solely by customer/industryrequirements.

Although the present invention has been described in relation toparticular embodiments thereof, many other variations and modificationsand other uses will become apparent to those skilled in the art. It ispreferred therefore, that the present invention be limited not by thespecific disclosure herein, but only by the appended claims.

1. An interlocking component assembly comprising: a plurality of framecomponents; a plurality of panels, each panel formed integrally with arespective frame to form a frame and panel component; and means forinterconnecting a plurality of assembled frame and panel components,said interconnecting means comprising a channel formed along the entireperiphery of each of the frame components, wherein during assembly thechannel of a frame component is inserted within a channel of anotherframe component to lock the components together along the lengththereof.
 2. The interlocking component assembly of claim 1, furthercomprising at least one locking tab disposed within the channel of eachof the plurality of frame components.
 3. The interlocking componentassembly of claim 2, further comprising at least one aperture disposedwithin the channel of each of the plurality of frame components, whereinwhen the channel of a frame component is inserted within the channel ofanother frame component the at least one locking tab is received withina corresponding aperture.
 4. A method of interlocking a plurality offrame and panel components comprising the steps of: providing aplurality of integral frame and panel components; and interconnecting aplurality of assembled frame and panel components, wherein each of theplurality of frames include a channel formed along the entire peripheryof each of the frame components, wherein during interconnection thechannel of a frame component is inserted within a channel of anotherframe component to lock the components together along the lengththereof.
 5. The method of claim 4, further comprising the step ofengaging at least one locking tab disposed within the channel of a framecomponent with at least one aperture formed within a channel of anotherframe component.
 6. The method of claim 5, wherein each of the steps isrepeated until a three-dimensional unit is formed.
 7. The interlockingframe and panel component unit of claim 6, further comprising at leastone sub-component disposed therein.